engine ISUZU KB P190 2007 Workshop Repair Manual

6A-66 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications





RTW 56AMF001701


Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2591-0
Camshaft gear tool


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-67
Valve Stem Seal and Valve Spring
Components




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Legend 1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Fuel Injector Assembly
6. Bolt
7. Fuel Injector Clamp 8. Pin
9. Spring Lower Seat
10. Valve Stem Oil Seal
11. Valve Spring
12. Spring Upper Seat
13. Split Collar
14. Valve Stem End Cap


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ISUZU KB P190 2007

6A-68 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the cylinder head.
Refer to “Cylinder Head”.
2. Remove the split collar. • Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)




RTW 56ASH012301
3. Remove the spring upper seat.
• Remove the special tool to remove the uppe
r
seat.
4. Remove the valve spring. Put the removed valve springs in order b
y
cylinder number.
5. Remove the valve stem oil seal. • Use pliers to remove the oil seal.





RTW 56ASH012401
Note:
Do not use the removed oil seal again.
6. Remove the spring lower seat.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-69
Inspection
Inspect the valve spring
Note:
Check the valve spring visually and if there is clea
r
damage or wear, replace it.
1. Free length • Measure free length of the spring and if it is
shorter than the prescribed limit, replace the
spring.

Free length of the valve spring
mm (in)
Inlet / Exhaust
Standard 49.04 (1.93)
Limit 48.15 (1.89)






LNW 21BSH017001
2. Valve spring squareness.
• Use a surface plate and a square to measure
the valve spring squareness.
If the measured value exceeds the specified limit, the valve spring must be replaced.
Valve spring squareness mm (in)
Limit 2.1 (0.083)





LNW 21BSH017101
3. Tension
• Use a spring tester to compress the spring to
the installation height. Measure tension of the
compressed spring. If the measurement is
lower than the limit, replace the spring.
Tension of the valve spring N (kg / lb)
Inlet / Exhaust
Installation length mm (in) 37.80 (1.488)
Standard 213 (21.7 / 47.8)
Limit 188 (19.2 / 42.3)







LNW 21BSH056701


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ISUZU KB P190 2007

6A-70 ENGINE MECHANICAL (4JK1/4JJ1)
Installation
1. Install the spring lower seat.
2. Install the valve stem oil seal. •
Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
Note:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted o
r
the garter spring has not come off.
Special tool
Valve stem seal installer: 5-8840-2817-0





RTW 56ASH013701
3. Install the valve spring.
4. Install the spring upper seat.
5. Install the split collar.
• Use a replacer to compress the valve spring
and install the split collar.

Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)





RTW 56ASH012301
Note:
Move it up and down to check if it moves smoothly.
6. Install the cylinder head.
Refer to “Cylinder Head”.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-71
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2818-0
Valve spring replacer

5-8840-2819-0
Pivot assembly

5-8840-2817-0
Valve stem seal installer


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ISUZU KB P190 2007

6A-72 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Head
Components





RTW 56ALF001001
Legend 1. Fuel Injector Clamp
2. Fuel Injector Assembly
3. Glow Plug
4. Intake and Exhaust Valves 5. Cylinder Head
6. Timing Chain Tension Lever
7. Timing Chain Guide
8. Timing Chain Tensioner

Note:
To avoid electric shock;
Set the switch to the 'OFF' position and disconnect the
negative battery cable before checking or repairing the
fuel injector, wiring or/and connectors. Removal
1. Remove the engine head cover.
2. Drain the engine coolant.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-73
3. Remove the radiator upper hose.








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4. Remove the fan guide.




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Legend
1. Fan Guide
2. Clips
3. Lower Fan guide
4. Fan Shroud


5. Remove the cooling Fan.





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6. Rotate the crankshaft to make the No.1 cylinder
meet the compression top dead center (TDC).





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Legend
1. TDC

7. Remove the A/C compressor drive belt.

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ISUZU KB P190 2007

6A-74 ENGINE MECHANICAL (4JK1/4JJ1)
8. Remove the A/C compressor adjust pulley.








RTW 56ASH010601
Legend
1. Bolt
2. Nut


9. Remove the battery.
10. Disconnect the A/C compressor connector and A/C compressor with hose.
11. Remove the A/C compressor bracket.





RTW 56ASH024201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor






12. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




RTW 76ASH000501
13. Remove the intake hose and duct (Standard
output).




RTW 56ASH022501
Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-75
14. Disconnect the fuel injector connector (2).
15. Remove the fuel leak off hose (1).







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Note:
Do not reuse the fuel leak off hose clips.
16. Disconnect each connector. • Glow Plug
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• W ater temperature sensor
• Camshaft Position sensor
17. Remove the harness bracket.
18. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
19. Remove the EGR cooler heat protector.
20. Remove the EGR cooler water pipe.
21. Remove the EGR cooler.


22. Loosen the nuts of catalyst converter and
turbocharger.



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Legend
1. Catalyst Converter
2. Turbocharger

23. Remove the exhaust front pipe.





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Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension, 4×4)
2. Exhaust Front Pipe (4×2 Except High Ride Suspension)




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ISUZU KB P190 2007